Devices and methods for heat-setting yarns

ABSTRACT

This invention is directed to flow management improvement to the known yarn texturing process, and is directed to devices and methods to accumulate one or more yarns between texturing device(s) and coiling device(s) prior to treatment in a heat-setting chamber. The devices and methods of the present invention may further provide for the removal of texturizing media from yarn prior to setting. The present invention allows for the deposition of yarn or yarns onto conveyor for a setting treatment to set an applied form to impart desirable properties to the yarn. The present invention may include any natural or synthetically produced yarn. The devices and methods of the invention may be used to improve the production capability of said heat setting and texturing equipment.

CROSS REFERENCE TO RELATED APPLICATION

This application claims benefit, under 35 U.S.C. §119(e), of U.S. Provisional Application Ser. No. 60/752,560, filed 20 Dec. 2005, the entire contents and substance of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to devices and methods for heat-setting yarn or yarns in the carpet making and textile arts and more particularly to devices and methods for providing textured yarn or yarns to a conveyer belt of a heat-treating chamber, which may provide production rates for textured yarn or yarns similar to rates usually associated with straight set yarn or yarns.

2. Description of Related Art

The esthetics and performance of carpet are similar in many respects to those of fabric used in clothing. The type of fiber used, the construction of cloth, and color all play a role in the styling, cost, and performance of a finished garment. Similarly, the styling, cost, and performance of finished carpet are affected by the type of fiber used in carpet yarn, how that yarn is used in constructing the carpet, and the finish characteristics of the yarn, including its color.

All carpet yarn may be manufactured from either Staple or Bulked Continuous Filament (BCF) fiber. Staple fiber is a series of relatively short, often 6 to 7 inches in length, filaments spun together to form one yarn bundle. Staple fibers typically arrive at a carpet mill in bales, which may be blended for uniformity. Staple fibers are then carded to make the fibers lie parallel to each other. A sliver or a continuous yarn is then formed of the fibers. Such slivers are then combed and stretched to a desired weight, usually in a pin-drafting process. A sliver may then be twisted in a spinning process either about its axis or together with one or more other strands of yarn to form a final strand of yarn.

BCF fiber is a continuous filament or filaments manufactured as one long string. These are twisted and heat-set together to form a strand of yarn. The yarn or yarns are joined at each end by a knot, splice or any acceptable means to facilitate processing. Both of these processes create yarns that produce carpet products with distinctly different looks and characteristics.

BCF fiber is formed into yarn bundles of a given number of filaments and texturized to increase bulk and cover. Texturizing changes the straight filaments into kinked or curled configurations.

Since BCF already arrives as a single yarn, it is often twisted with another yarn or yarns (two or more-ply) and bulked before being heat set. Single yarns may be twisted about the axis of said yarn in the case of a one ply or “singles” yarn. Bulking is processing yarn to fluff it up and give more coverage with the same weight. Bulking typically causes a carpet fiber or yarn to decrease in length and increase in cross section or modulus diameter. Crimping creates “creases” in individual filaments and thus yarn or yarns by creating a saw-tooth, zigzag, or random curl relative to the axis of the yarn.

Carpet yarns may generally be heat-set if used in cut pile carpet, but may not be heat-set if used in loop pile constructions. The process used to set the twist in the yarn generally involves heat and sometimes moisture. Heat setting adds to and improves fiber resiliency. It may also impart improvements in dye affinity or uptake of the fiber.

Thus, making carpets typically includes the steps of twisting, heat-setting, tufting, dyeing and finishing. In particular, heat-setting of twisted yarn is an important step in converting BCF yarns to carpets. Heat-setting develops crimp and locks the twist memory in the BCF yarns. The development of crimp and twist memory have a significant impact on yarn bulk and newness retention of finished carpets.

In the conventional texturing process, the yarn is provided to the heat-setting machine via a conveyer belt. The yarn is piddled in a spaghetti-like pattern onto a flat conveyor belt. The conveyor belt carries the yarn through the heat-setting chamber in the spaghetti-like pattern so that it is heat set with relatively high crimp.

For approximately three decades the carpet industry has been making a variety of products with various yarn or yarns from various fiber or fibers that gives finished carpet a trackless appearance. The above-discussed process of twisting together one or more yarns, and then texturing them on a variety of texturing machines, imparts this property. Yet, this property has always been limited by factors of production that do not allow for similar rates of production of “textured” or friezed yarns as with so called “straight set” yarns.

There are three general heat-setting methods: Autoclave (steam and pressure in a batch process), Superba® (continuous steam and pressure), and Suessen® (dry heat). Heat setting allows the yarn to retain its shape and twist. The yarn then usually goes to a tufting machine.

The original heat-setting process was batch related and labor intensive. The use of a pressure vessel or autoclave allowed the thermosetting. In the mid 1970's, the French, Superba®, continuous process, was developed. Shortly thereafter, the German, Suessen® process was developed.

The autoclave process uses steam in a pressure vessel. Time and temperature of the autoclave cycle provides the desired properties that gives the yarns a “memory” for crush resistance to normal foot traffic, a desirable visual appearance, and characteristics of other desirable properties.

The other types of heating-setting methods are typically used in continuous heat-setting machines, the Superba® and Suessen® methods. The first type uses pressurized steam (i.e., saturated or near saturated steam), wherein the most common pressurized steam heat-setting machine is referred to as a Superba® machine, and is made by Superba® of Mulhouse, France and represented in the United States by America by Superba®, Inc. of Dalton, Ga. An exemplary Superba® heat-setting machine operates with a maximum temperature of 154° C., typically in the temperature range from 120° C. to 140° C., and with a maximum pressure of 65.26 psi, typically in the pressure range from 22 to 37 psi.

The Superba® machine uses a pressure vessel with a stainless steel belt through a pair of tightening or sealing heads on each end of a long pipe. The heads use rubber-coated rollers and Teflon® impregnated lateral and longitudinal plates to seal the rubber rollers. The rollers are also pressed together mechanically.

For better understanding of later descriptions, the pipe also employs a cooling chamber both before and after the heat zones of the machine to protect the rubber pieces from excessive heat. After a period of time, it was made apparent that the cooling chamber conditions could also impart desirable properties to the yarns, in addition to also protecting the rubber machine parts.

The original Superba® machine, referred to as TVP (Tunnel de Vaporisage sous Pression) ran six yarns. Later it was upgraded to nine, and then 12 ends. Later the number of yarns was increased to 18, 24 and then 36 ends. One machine made use of 42 ends for a period of time.

The current state of the art is 48 ends of yarn. Later advances in methods for moving the steam texturing media or CBS (Circulation Brassage System) unit were invented and applied or retrofitted to the current and older machines.

In the early 1990s, a shell within a shell design was adopted for both the pre-steaming unit on the machine and also for the cooling chambers. This new presteamer allowed for better and more consistent steaming or “bulking” of the yarns. Likewise, the cooling chambers were upgraded and the relatively cool texturing media could be circulated through the yarn bundle.

The second type of heat-setting method uses hot air at atmospheric pressures. The most common hot air atmospheric pressure heat-setting machine is referred to as a “Suessen®” machine, and is made presently by Power Heat Set of Germany. An exemplary Suessen® heat setting machine operates in the temperature range of 160° C. to 210° C.

The Suessen® machine uses a different method for the setting process than does the Superba® machine. A “box” is employed with six chambers. Each chamber has a series of Nomex® ropes or a Kevlar® belt passing through it. The yarn bundle is deposited on the ropes or belt and passed through a “dry” mixture of steam. Contrary to the Superba® machine that uses a “wet”0 process of steam, the Suessen® machine is heated either by a non-direct thermal fluid texturing media or by electric resistance rods.

The Suessen® machine evolved along with the Superba® machine, beginning with one end per chamber at the beginning of the Suessen® era, and then progressing to allow for multiple ends. The current state of the art in Suessen® technology uses eight ends per chamber. The current machine is also double the original's length to allow for faster transportation through the chamber.

The crystalline structure of heat-set yarns and the end use performance of the finished carpets produced from heat-set yarns primarily depend on the heat-setting method used in producing the yarn or yarns. In general, carpet yarns produced by hot atmospheric air heat-setting machines (e.g., Suessen®) have higher bulk and better stain resistance than carpet yarns produced by pressurized steam heat-setting machines (e.g., Superba®).

In a typical process, the yarn is passed through a heated chamber, while in a relaxed condition. The temperature of this process step is crucial to the proper twist setting of the base fiber, to obtain desired properties of the final carpet product. As an example, for nylon-6 base fiber, the conditions for this step typically involve a residence time of about 60 seconds at temperatures of about 190-200° C. for the Suessen® process, and a residence time of about 60 seconds at about 125-140° C. for the Superba® process. The Superba® process utilizes saturated steam and thus the yarn is subjected to a much higher level of humidity than in the Suessen® process.

Improvements by both Suessen® and Superba® have allowed for faster conveyor speeds through their respective machines. Larger and wider machines have also helped with production rate and volume increases. Yet, limitations on production still exist. Textured yarn production capacity has indeed improved, but not to the extent of straight set yarn production.

Therefore, it may be seen that a need yet exists for a more productive texturing process, which may provide substantially the same production rates for textured yarns as for straight set yarns. It is to such a process that the present invention is primarily directed.

BRIEF SUMMARY OF INVENTION

Briefly described, an exemplary embodiment of the present invention are devices and methods for improving the production for textured yarns, which improvement is generally located between the texturing machine and the heat-setting machine in a carpet mill, comprising the following steps: steam addition, accumulation, steam removal, and coiling. An exemplary device of the present invention is a J-Box mechanism.

Prior to the present invention, the conventional yarn texturing process comprised taking twisted or air entangled yarns, and loading them onto a creel or magazine. The yarns were then drawn together on a pre-feeding device, and then to a texturing machine. The yarns were then slid down a chute to the conveyor belt of a heat-setting machines; for example, the stainless steel belt of the Superba® machine, or the Kevlar® belt of the Suessen® machine. A problem with this conventional process is the relatively low production rates, as the yarn was deposited onto the belt from the texturing machine in a non-preferred manner.

Thus, it is an object of the present invention to improve the production rates of textured yarns.

The present invention is directed to devices and methods for taking friezed yarns and depositing yarns to a conveyer belt of a heat-setting machine in a new and non-obvious manner, providing for increased production over conventional methods. Using the devices and methods according to the present invention, yarn may be laid in more mass than conventionally possible, thus achieving both production advantages and cost savings.

In the devices and methods according to the present invention, a texturing media (e.g., steam) may be provided to yarns within a texturing device. While steam is an exemplary medium, other texturing media may be used to impart beneficial setting properties, including other fluids, gases, steam or vapor, which might be acceptable to produce a textile material with desired finished properties. Applications employing solid texturing media may also be made. The texturing media may or may not sublimate during the process or upon entrance, exit or in-between the entrance and exit of a J-Box mechanism located downstream of a texturing device. Devices and methods according to the present invention may also comprise a lubricant which may be applied to yarn in either wet or dry form.

Additional exemplary aspects of the devices and methods of the present invention may include the steps of yarn accumulation and texturing media removal. These steps may occur in a J-Box mechanism of the present invention. An exemplary J-Box has a tubular housing comprising a length of pipe with an elbow and guide, having an entrance, an exit, and a lumen therethrough to allow the transit of yarn within the tubular housing. The tubular housing may have various alternative cross-sections; in an exemplary embodiment, such a tubular housing may be round. Various embodiments of J-Box mechanisms of the present invention may be straight, curved, arcuate, helical, or non-straight tubular housings with hollow lumens through which yarn may be transported on a conveyor for treatment. Within an embodiment of a J-Box mechanism of the present invention, steam or other media may be removed from yarns, and the yarns may be accumulated for subsequent thermal or non-thermal setting treatments. Textured yarns are inserted into the entrance of the J-Box after undergoing texturing in a texturing device, and are then accumulated. The yarns are accumulated in the J-Box, but limited from tumbling and tangling by an accumulation control device, such as a flap, roller system, or series of rods that keep the yarn from tumbling upon itself, which may result in undesired tangling.

At an exit end of the tubular housing of an exemplary J-Box, an elbow is provided. Such an elbow may provide an angled or arcuate exit. In an exemplary J-Box of the present invention, a ninety (90) degree elbow may be provided, although other orientations may be used. The elbow may be fabricated of the same material as the tubular housing, or it may be fabricated of differing material. At the exit end of the elbow, a guide may be mounted thereto to facilitate the smooth removal of accumulated yarn or yarns. In various embodiments of the present invention, such a guide may be porcelain, or may be constructed from other materials that would tend to not cause undue abrasion to the yarns that might make them less desirable. If yarn abrasion should be desired in a particular circumstance, a rougher textured guide may be utilized according to the present invention.

Exemplary devices and methods of the present invention may also comprise a step of texturing media removal within a J-Box mechanism as described. In an embodiment of the present invention, steam may be removed from a J-Box mechanism through portals in the pipe portion or the elbow portion using a blower/fan, suction/fan, or other gas moving device. The portal size(s) and portal pattern(s) may include various embodiments, but must be suitable for the proper removal of steam from the yarns. Removal of steam in the J-Box mechanism helps retain the deposited crimp of the yarns.

Some embodiments of the devices and methods of the present invention are provided for situations that may not require the removal of steam, or other texturing media. If a “near textured” appearance were desired, texturing media removal may not be necessary. Yet, in other embodiments of the present invention, texturing media removal is desirable to make a product that may retain all or at least a large majority of the added texture. The devices and methods of the present invention produce finished carpet products with improved “tip definition.” This tip definition quality is typically associated with a better valued or higher quality carpet product.

Embodiments of the devices and methods of the present invention may further be provided with one or more guides located between a J-Box mechanism as described herein and a coiler. Such guides may be made of a solid wax or solid fiber lubricant material, to further aid in the processing of the yarn or yarns to impart desired finished qualities therein.

In various embodiments of the devices and methods of the present invention, upon exiting the J-Box, yarn or yarns may pass through a guide or series of guides that eventually terminate in a coiling mechanism. The coiling mechanism may deposit the yarn or yarns onto the stainless steel belt of the Superba® machine or the Kevlar® belt of the Suessen® machine. The coiling action of the present invention enables for increased productivity in the operation of the heat-setting process, wherein the unwinding of the yarn bundle is smoother, and there are fewer faults on the heat-setting machine.

This and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of the various steps of an exemplary embodiment of the present invention.

FIGS. 2A and 2B are views of the J-Box mechanism of an exemplary embodiment of the present inventions.

FIG. 2C is a detailed view of FIG. 2A showing an embodiment of an accumulation control device of the present invention.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

The present invention may be understood more readily by reference to the following detailed description of various embodiments of the invention and the examples included herein. However, before these embodiments of the devices and methods according to the present invention are disclosed and described, it is to be understood that this invention is not limited to the exemplary embodiments described within this disclosure, and the numerous modifications and variations therein that will be apparent to those skilled in the art remain within the scope of the invention disclosed herein. It is also to be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting.

Unless otherwise noted, the terms used herein are to be understood according to conventional usage by those of ordinary skill in the relevant art. In addition to the definitions of terms provided herein, it is to be understood that as used in the specification and in the claims, “a” or “an” may mean one or more, depending upon the context in which it is used. Furthermore, it is to be understood that the terms “yarn” and “yarns” are to be used interchangeably herein, and refer to aggregates of one or more fiber components twisted or otherwise aggregated into one or more strands.

Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, FIG. 1 illustrates an exemplary device and method of the present invention 10 for the accumulation of a textured yarn or yarns to be applied to a coiler or coiling mechanism. The improvements of the present invention generally include providing steam or other texturing media to the texturing process of yarn, then delivering the yarn to a J-Box mechanism or other device of the present invention, wherein textured yarn may be accumulated, steam removed, and then delivered to a coiler.

FIG. 1 provides an exemplary illustration of yarn Y entering a texturing or frieze machine 100, wherein steam S is provided. In embodiments of the present invention, the steam may be “pure” steam, and delivered to the texturing machine 100 from a textile or carpet mill's existing steam piping.

Embodiments according to the devices and methods of the present invention may employ steam or other texturing media in which all or mostly all the water content or condensate has been removed. Such steam or texturing media may be delivered through piping which may be conventional, commercially available piping implements. Removed water or condensate may then flow out to a drain. The steam or other texturing media pressure may be lowered gradually by one or more commercially available regulators, strainers, and traps. Embodiments of the present invention may prevent “superheating” of steam or other texturing media by backpressure at a small orifice or orifices. The steam or other texturing media actually delivered to the texturing machine may be of a desired and appropriate quality for the application.

Again referring to FIG. 1, after leaving the texturing or frieze machine 100, textured yarn TS then enters a J-Box mechanism 200. Further details of an exemplary J-Box mechanism 200 of the present invention are provided in FIGS. 2A and 2B. FIG. 2A is a front view, and FIG. 2B is a side view of a disclosed embodiment of a J-Box mechanism 200, comprising a tubular housing 210 containing a lumen therein, an elbow portion 220, a sensor 230 used to control output from the frieze machine 100, an eyelet 240, an aperture 250 enabling the sensor 230 to monitor the yarns, but also enabling some steam or other texturing media to escape, an accumulation control device 260 to provide for the orderly accumulation of the yarns, and a texturing media removal system 300, which may comprise a combination of portals 310 in the J-Box, in combination with a fan 320.

The control of sensor 230 controls the input to the J-Box mechanism 200 electrically or electronically by sending a signal to the texturing or frieze machine 100 to go to a higher or lower speed. At least two speeds “high” and “low” are enough to control the input in some embodiments of the present invention. In other embodiments of the present invention, the control of sensor 230 controls the input to the J-Box mechanism 200 electrically or electronically by sending one or more signals to the texturing or frieze machine 100 which is capable of either continuous or multiple stepwise increases and decreases in input to the J-Box mechanism 200. A more robust system could ramp up or down in a more “fancy” way, but it is not necessary. In some embodiments of the present invention, the transit time for fibers through the J-Box mechanism 200 may be approximately constant as a gravitational effect, and relatively unaffected by input speeds from the texturing or frieze machine 100. In other embodiments of the present invention, the control of sensor 230 may control the transit time of fibers through the J-Box mechanism 200 electrically or electronically by sending a signal to a pneumatic pump, variable speed conveyor device, or other J-Box mechanism transit device [devices not shown in these drawings] to operate to produce a longer or shorter transit

An accumulation control device 260 in various embodiments of the present invention may be an articulated flap or a system of one or more rollers which serve to tamp down or flatten the accumulated fibers within the J-Box mechanism 200 as described. As shown in FIG. 2C, an example of an accumulation control device 260 of the present invention is an open flap comprising a bent rod 265 configured to articulate on pivoting brackets 270 within the tubular housing portion 210 and presenting a flattening surface in contact with the flow of yarns therein. In other embodiments not shown in the present figures, such an accumulation control device 260 may be a sold flap, or a roller mechanism to flatten the mass of the accumulated yarn fibers. Such an accumulation control device 260 may be controlled by gravity in some embodiments of the present invention. In other embodiments of the present invention, an accumulation control device 260 may be controlled mechanically, electronically, or electromechanically to provide a specific desired flattening effect to prevent tangling and enhance results.

In various exemplary embodiments of the present invention the tubular housing portion 210 and elbow portion 220 may be constructed of metal, metal alloys, ceramics, glass, Plexiglas, polymers, other natural or synthetic materials, or composites or combinations thereof. Similarly, in various embodiments according to the present invention, the eyelet 240 serves to allow yarn egress, and may be ceramic or porcelain. In yet other embodiments of the present invention, the eyelet 240 may be constructed of other materials, including metals, metal alloys, polymers, other natural or synthetic materials, or composites thereof, of qualities desired to produce certain qualities in the finished product.

In other various exemplary embodiments of the present invention the J-Box mechanism 200 may comprise a tubular housing portion 210 containing a lumen therein, but without an elbow portion. In such embodiments, the tubular housing 210 may be curved, straight, angled, helical, arcuate, or otherwise shaped.

In exemplary embodiments of the devices and methods of the present invention, the J-Box mechanism 200 serves to both appropriately hold the yarn or yarns in transit through the lumen of the tubular housing 210 and allow it/them to be taken up by the coiler 500 (or other means to be applied to the conveyor media), and to remove desired amounts of steam or other texturing media.

The sensor 230 is but one of several control mechanisms that may be included in various embodiments of the present invention for the management of flow of yarn or yarns through the finishing process, and to provide control for the upstream and/or downstream processes. In various embodiments of the present invention in which a J-Box mechanism 200 comprises translucent and/or transparent portions, an aperture 250 may be unnecessary, as the sensor 230 may be able to see “through” an appropriately configured J-Box mechanism 200.

The control mechanisms in various embodiments of the present invention may be as sophisticated as computer controlled means, or as simple as a fan moving at an assigned and rated speed, based on electrical current frequency and voltage. An inverter with an internal or external potentiometer may provide a means of control in embodiments of the present invention, and is of nominal sophistication.

Returning to FIG. 1, the yarns exit the J-Box mechanism 200 through appropriate guiding elements 400 to prevent tangles and inadvertent crossings. The yarns enter a commercially available coiler 500 in a normal fashion, consistent with the precedents set by that particular coiler's manufacturer. Embodiments of the present invention employ belt mass loadings in the range of about 1 to about 1000 grams per meter. Embodiments of the present invention employ belt mass loadings in the range of about 100 to about 400 grams per meter. The belt mass loadings are consistent with established norms of straight set processing. The resultant productivity is consistent with belt mass loadings for straight set yarns. The yarn is then coiled, and thereafter deposited to a heat-setting machine 600 via conveyor 610.

The conveyor 610 may be a stainless steel belt 610 comprised of any of a number of readily-available perforation patterns, or may be a solid band without perforation of any type. It may be of any desired suitable length or width.

As disclosed herein, yarn treatment may comprise a batch or continuous method of processing.

The devices and methods of the present invention allow for yarns to be applied to a conveyor comprising many belt materials or types. Weave structure; knit structure or non-woven structural materials may be used as conveyors in various embodiments, as well as stainless steel, ferrous or non-ferrous metals.

The devices and methods of the present invention are not specific to use of any particular opening pattern in the conveyor, although certain particular aspects of a conveyor may impart particular benefits to the finished product of a specific application, and may thus be employed in various embodiments depending upon such desired benefits.

Conventional attempts at coiling yarns after texturing proved unsuccessful as the yarns did not retain the texture, and further failed to deposit the yarns in a way that might be properly coiled. There was no improvement to be gained by texturing, texture removal and coiling. The yarns kept the straight appearance of the straight set coiling.

Differences between the devices and methods of present invention and other process include the accumulation of textured yarn, and the subsequent coiling. This enables higher productivity in the yarn processing. The devices and methods of the present invention further provide styling effects that are not possible with a straight set or normal textured product.

The present invention includes various alternate embodiments of its devices and methods. For example, in some situations, more than one J-Box mechanism 200 may be used in series or in parallel as desired to increase productivity. Further, yarn or yarns may be coiled and then recoiled as a part of the present process. Such an exemplary method may employ a treatment, and then movement to a separate J-Box mechanism, and then back to a coiler. Such movement between coilers may impart desirable properties.

Such multiple coilings may take place on any vertical or horizontal material, woven, knitted, nonwoven, or of some ferrous or nonferrous metal of high nickel and chromium content. Such metal embodiments may utilize openings of a certain pattern or perforations of a certain patterned structure. A conveyor of the present invention may comprise a woven, knitted, or non-woven material belt which may incorporate particular openings pattern.

Embodiments of the present invention may further comprise a feeding device to improve the texturing machine's performance. Embodiments of the present invention may or may not further comprise a positive texturing media removal device while the yarn or yarns are gathered in the texturing machine or machines.

Further, while embodiments of the present invention may employ steam or other texturing media, a single setting or texturizing method is not specific according to the present invention. Setting or texturizing methods of the present invention impart thermoplastic properties or thermosetting properties to fibers depending upon the properties of the particular fibers. Setting or texturizing methods of the present invention may comprise a heated or cooling method to impart the desired properties, or may rely upon a non-thermal setting or texturizing process.

While embodiments of the present invention may employ a steam removal system 300, other embodiments may comprise other media removal systems to remove fluid, gas, vapor or steam texturing media. An exemplary steam removal system 300 is disclosed as using a fan assembly to remove the texturing media to a location distant to the J-Box mechanism, such as venting to the ambient atmosphere. Other texturing media removal systems of the present invention may comprise recovery devices that may be used to capture and recycle any texturing media removed from the J-Box mechanism, including non-environmentally friendly texturing media.

Devices such as servomotors may be used in embodiments of the present invention to impart a multiple and varied texturing media removal mechanism. Such multiple and varied texturing media removal mechanisms may impart desired qualities to the finished yarn or yarns that might differ from the products of continuous methods of texturing media removal. These properties may impart a specific “novelty affect” to the materials.

In various applications of use, removal of the fluid, gas, vapor, steam, or other texturing media may impart desirable or non-desirable characteristics to the finished yarn or yarns. Similarly, in certain applications of use, non-use and or removal of a sublimating or non-sublimating, wet or dry texturing media may impart desirable or non-desirable characteristics to the finished yarn or yarns. Further, use and removal of a sublimating or non-sublimating, wet or dry texturing media may impart desirable or non-desirable characteristics to finished yarn or yarns in various applications. Therefore, embodiments of the present invention for certain applications may provide for non-removal of the fluid, gas, vapor, steam, or other texturing media, when such non-removal may impart desirable characteristics to finished yarn or yarns.

While the invention has been disclosed in its preferred forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions may be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. 

1. A device for use in the heat setting of one or more yarns, said device interposed between a texturing/frieze machine and a coiler, and comprising an accumulation control device to provide yarn flow management between the texturing/frieze machine and the coiler, and a texturing media removal system to remove at least a portion of the texturing media provided to the yarns from the texturing/frieze machine.
 2. The device of claim 1, wherein said device further comprises a tubular housing through which the one or more yarns pass.
 3. The device of claim 1, wherein said texturing media is steam.
 4. The device of claim 1,wherein said device further comprises an aperture.
 5. The device of claim 2, wherein said texturing media removal system comprises one or more portals in said tubular housing.
 6. The device of claim 5, wherein said texturing media removal system further comprises an exhaust fan in communication with one or more of said portals, said fan moving at a desired speed, based on electrical current frequency and voltage.
 7. The device of claim 1, wherein said accumulation control device comprises an output control sensor in electrical communication with a control system to monitor and control yarn output from said texturing/frieze machine and/or transit time for said one or more yarns through said device.
 8. The device of claim 7, wherein said accumulation control device further comprises an aperture in said tubular housing for the operation of said sensor.
 9. The device of claim 7, wherein said control system is computer controlled.
 10. The device of claim 2, wherein said tubular housing further comprises a tubular housing with an elbow portion
 11. The device of claim 2, comprising two or more tubular housings, accumulation control devices, and texturing media removal systems, arranged in parallel operation.
 12. The device of claim 2, comprising two or more tubular housings, accumulation control devices, and texturing media removal systems, arranged in serial operation.
 13. A method of heat setting one or more yarns comprising the steps of: receiving yarns from a texturizing/frieze machine in which said yarns were treated with texturing media; accumulating said yarns within a tubular housing in a controlled manner; removing at least a portion of said texturing media from said yarns, and delivering said yarns to a coiler.
 14. A method of attaining desired characteristics in a woven product, wherein said product is fabricated from one or more texturized yarns, comprising the steps of: texturizing yarns with texturing media within a texturizing/frieze machine; accumulating said texturized yarns within a tubular housing in a controlled manner; removing at least a portion of said texturing media from said yarn; delivering said yarns to a coiler; and, depositing said coiled yarns to a heat-setting machine.
 15. A method of increased production of one or more yarns with desired texturized properties, comprising the steps of: texturizing yarns with texturing media within a texturizing/frieze machine; accumulating said texturized yarn within two or more tubular housings in a controlled manner; removing at least a portion of said texturing media from said yarns; delivering said yarns to a single coiler; and depositing said coiled yarns to a heat-setting machine via a conveyor. 